基于FPGA的TOFD超声焊缝探伤数据采集系统设计
摘要
超声波TOFD (Time Of Flight Diffraction)法,即超声衍射时差探伤法,是利用衍射回波信号进行缺陷判别的一种非常有效的无损检测方法,在现今国内外已成为研究的热点。它具有检测速度快、精度高、缺陷检出率高、尺寸与定位准确、经济方便等优点。
本文就是针对在TOFD超声焊缝探伤的背景下,设计了一种数据采集系统。该设计基于FPGA,并在USB2.0Slave FIFO传输模式下,对前端检测的数据进行A/D转换,并将数据传输到PC机中。同时还搭建了基于Olympus(奥林巴斯)公司的Focus-LT设备的另一个实验平台,与本设计所采集到的数据进行了对比。
首先,在详细调研了TOFD关键技术与数据采集方式的基础上,确定了总体方案。包括硬件电路总体方案和数据的传输和处理流程,
其次,概述了USB技术原理。基于CY7C68013芯片,采用USB2.0高速传输模式,利用USB Slvae FIFO传输方式,编写了其固件程序,配置了控制芯片的通道、端点、中断等参数。
第三,设计硬件电路,A/D采样电路,和在FPGA中利用VHDL语言设计了各时序逻辑模块,如时钟模块、控制模块、FIFO缓冲模块以及Slave FIFO时序控制模块等。
最后,进行了实验系统的测试,对FPGA配置芯片、USB控制器、超声探头、编码器器件选型,实现了速度基本为40M/s的数据传输速率。并利用Focus-LT设备搭建了另一个TOFD检测试验平台,进行焊缝缺陷的检测与数据采集,得到了检测的A扫和D扫图像,并对比分析了两组实验的数据。
TOFD (Time of flight diffraction) is one of the most advanced technologies in the industry field of ultrasonic nondestructive detecting. Sizes and locations of flaws could be gotten according to the difference between the time-intervals of return diffraction signals from the tips of flaw. It has been widely used in weld flaw detecting currently at home and abroad. There are many remarkable advantages such as highly detecting speed, precision, detectable rate, accurately locating flaws and convenience, etc.
It designed a data collection system based on the TOFD ultrasonic weld flaw detecting. It collects analog data and transforms them to digital, using Slave FIFO transportation model in USB and FPGA to transport them to PC. Meanwhile, another experiment platform is set up with Focus-LT equipment which is made by Olympus Company, getting data and images to compare with this design.
Firstly, the overall implementation scheme of the data collection system is presented, including hardware circuit plan, way of transportation and processing data, and the type of FPGA chip, USB controller, probe, encoder, etc.
Secondly, USB theory is summarized firmware program in USB Slvae FIFO model based on CY7C68013is composed. Parameters like pipes, interfaces and interrupts are set.
Thirdly, A/D data sampling circuit and modules based on FPGA which used VHDL language is designed, including clock module, controlling module, FIFO and Slave sequence controlling module.
At last, after the debug of hardware&software is completed, components and chips are chose, transmitting speed is above40M/S. Meanwhile, another detecting experiment platform is set up with Focus-LT, data from two suits of experiment platform are compared. As expected, results demonstrate the correctness and applicability.
本文就是针对在TOFD超声焊缝探伤的背景下,设计了一种数据采集系统。该设计基于FPGA,并在USB2.0Slave FIFO传输模式下,对前端检测的数据进行A/D转换,并将数据传输到PC机中。同时还搭建了基于Olympus(奥林巴斯)公司的Focus-LT设备的另一个实验平台,与本设计所采集到的数据进行了对比。
首先,在详细调研了TOFD关键技术与数据采集方式的基础上,确定了总体方案。包括硬件电路总体方案和数据的传输和处理流程,
其次,概述了USB技术原理。基于CY7C68013芯片,采用USB2.0高速传输模式,利用USB Slvae FIFO传输方式,编写了其固件程序,配置了控制芯片的通道、端点、中断等参数。
第三,设计硬件电路,A/D采样电路,和在FPGA中利用VHDL语言设计了各时序逻辑模块,如时钟模块、控制模块、FIFO缓冲模块以及Slave FIFO时序控制模块等。
最后,进行了实验系统的测试,对FPGA配置芯片、USB控制器、超声探头、编码器器件选型,实现了速度基本为40M/s的数据传输速率。并利用Focus-LT设备搭建了另一个TOFD检测试验平台,进行焊缝缺陷的检测与数据采集,得到了检测的A扫和D扫图像,并对比分析了两组实验的数据。
TOFD (Time of flight diffraction) is one of the most advanced technologies in the industry field of ultrasonic nondestructive detecting. Sizes and locations of flaws could be gotten according to the difference between the time-intervals of return diffraction signals from the tips of flaw. It has been widely used in weld flaw detecting currently at home and abroad. There are many remarkable advantages such as highly detecting speed, precision, detectable rate, accurately locating flaws and convenience, etc.
It designed a data collection system based on the TOFD ultrasonic weld flaw detecting. It collects analog data and transforms them to digital, using Slave FIFO transportation model in USB and FPGA to transport them to PC. Meanwhile, another experiment platform is set up with Focus-LT equipment which is made by Olympus Company, getting data and images to compare with this design.
Firstly, the overall implementation scheme of the data collection system is presented, including hardware circuit plan, way of transportation and processing data, and the type of FPGA chip, USB controller, probe, encoder, etc.
Secondly, USB theory is summarized firmware program in USB Slvae FIFO model based on CY7C68013is composed. Parameters like pipes, interfaces and interrupts are set.
Thirdly, A/D data sampling circuit and modules based on FPGA which used VHDL language is designed, including clock module, controlling module, FIFO and Slave sequence controlling module.
At last, after the debug of hardware&software is completed, components and chips are chose, transmitting speed is above40M/S. Meanwhile, another detecting experiment platform is set up with Focus-LT, data from two suits of experiment platform are compared. As expected, results demonstrate the correctness and applicability.
引文
[1]中国机械工业学会无损检测分会.超声波探伤.机械工业出版社,2005
[2]白艳.基于TOFD法的钢结构焊缝超声无损检测研究.东北林业大学硕士论文.2011：1-15
[3]马崇,吴振勇,宋力宏TOFD检测技术及测管装置.2003苏州无损检测国际会议论文集,2003：29
[4]Cho K, Hiroak,i Hisash. i Development of Simplified Ultrasonic CT System for Imaging of Weld Metal and Its Comparison with TOFD Method. JSME International Journal,2002,45(2):262-267
[5]李生田,刘志远.焊接结构无损检测技术.北京：机械工业出版社,2000
[6]白艳,邢涛.焊接结构超声TOFD法的研究现状及展望.森林工程.2010,26(5)：32-35
[7]李忠,贺艺科,等.工业管道相关标准中的无损检测要求.无损检测.2003,25(11)：597-599
[8]韩相勇,姜自安,韩曙光,等.超声TOFD技术在管道环焊缝检测中的应用.无损检测.2008,30(1)：61-63.
[9]郭学,超声TOFD方法在管道弯头检测上的应用.无损探伤.2008,32(2)：35-36.
[10]T. Miliara, Y.Otsuka and H. CHo. Time of Flight Diffraction Measurement Using Laser Ultrasound. EX Penmenial Mechanics.2006, (46):561-567
[11]B. Messer, M. Yarmuch, P.Boer. High Resolution Detection for Thermoplastic Butt-Welds in Operating Pipelines by Ultrasonic TOFD. New Pipeline Technologies, Security, and Safety.2003(1):394-399.
[12]G.Baskaran, K. Balasubramaniam and C. L.Rao. Shear-wave Time of Flight Diffraction Technique. NDT and E International.2006,6(39):458-467
[13]W. Lawson, W. Lawson. Deteetion of Defeetsin Industrial Ultrasound Images Using a Neural Network. Proceedings of SPIE-The Intemational Society for Optical Engineerin.1996, (2786):37-47
[14]P. Moura, R. Silva and H. S. Siqueira. Patten Recognition of Weld Defects in Preproeessed TOFD Signals Using Linear Classifiers. Journal of Nondestructive Evaluation.2004,23(4):163-172
[15]T. Chen, P. Que and Q. Zhang. Ultrasonic Signal Identification by EmPtrieal Mode Decomposition and Hilbert Transform. American Institute of Physies. 2005,76(8):594-600
[16]G. Baskaran, K. Balasubramaniam and C. V. Krishnamurthy. UltraSOic TOFD Flaw sizing and Imaging in Thin Plates Using embedded Signal Identification Technique. Insight Non-Destructive Testing and Condition Monitoring. 2004,9(46):537-542
[17]李衍.超声TOFD法的基础试验.无损探伤.2003,27(2)：1-10
[18]迟大钊,刚铁,等.面状缺陷超声TOFD法信号和图像的特征与识别.焊接学报.2005,26(11)：1-5
[19]刚铁,迟大钊,等.基于合成孔径聚焦的超声TOFD检测技术及图像增强.焊接学报.2006,27(10)：7-10
[20]龚铭,朱杰.边缘检测在TOFD扫描图像中的应用.电子测量技术.2007,30(7)：5-10
[21]吴军芳,滕永平,等TOFD探头性能测试及其衍射特性的研究.无损检测.2006,28(2)：64-67
[22]曹明,王巍,等.反求工程在超声衍射时差法三维建模中的应用.无损检测.2006,28(2)：73-74
[23]李衍.薄板试件的超声TOFD法缺陷定量和成像.无损探伤.2005,29(5)：1-5
[24]强天鹏,肖雄,李智军等TOFD技术的检测盲区计算和分析.无损检测.2008,30(10)：738-740
[25]StratixII GX, www.altera.com
[26]Wang Xuying, Zhang Likun, Lu YingHua. Design and implementation of high-speed real-time data acquisition system based on FPGA [J]. Journal of China Universities of Posts and Telecommunications.2006, 13(4): 61-66.
[27]田书林,王志刚,王厚军.一种多通道高速数据采集精密同步设计方法.计量学报.2010,31(1)：68-70.
[28]买培培,苏涛,齐红涛.基于FPGA的多路信号处理设计.雷达科学与技术.2010,8(3)：234-238.
[29]Yang Shujie, Guo Zonglian. Development of high-speed data acquisition system based on FPGA[J]. Electric Power Automation Equipment.2008,28(6): 93-96.
[30]江明.基于FPGA的高速数据采集系统的研制.哈尔滨理工大学硕士学位论文.2011：1-4
[31]马明建.数据采集与处理技术.西安：西安交通大学出版社,2005
[32]苏涛,张海峰,张登福.基于USB总线的实时数据采集系统设计与实现.电子技术应用.2004.
[33]诸振勇,翁木云FPGA设计及应用.西安：西安电子科技大学出版社,2002：112-207.
[34]丁安扬.基于FPGA与USB的数据采集系统的研究.成都理工大学硕士学位论文.2011
[35]冯若.超声手册.南京：南京大学出版社,2001：121-127
[36]亢彦军.超声TOFD法焊缝探伤系统的研究及开发.天津大学硕士学位论文.2007
[37]陈智发TOFD超声检测系统的研制.汕头大学硕士学位论文.2011
[38]Shyamal Mondal, Dr.T. Sattar, An overview TOFD method and its Mathe-matical Model, NDT, 2000, vol.5: 83-87
[39]钱峰.EZ-USB FX2单片机原理、编程及应用.北京：北京航空航天大学出版社,2006
[40]周立功等.USB固件编程与驱动开发.北京：北京航空航天大学出版社,2005,2
[41]Cypress. CY7C68013, EZUSB FX2 USB Microcontro] ler, www.cypress.com,2006
[42]薛圆圆.USB应用开发技术大全.北京：人民邮电出版社,2005,3
[43]Altera Corporation. Cyclone III Handbook, Volume 2, 2009, 12 http://www.altera.com.cn.
[44]张永军.基于FPGA的图像处理系统设计与算法实现研究.重庆大学硕士学位论文.2006：16-18
[45]赵宇玲.基于FPGA的信号采集与处理系统设计与实现.南京理工大学硕士学位论文.2008
[46]王诚,吴继华等AlteraFPGA/CPLD设计(基础篇).北京：人民邮电出版社.2005
[47]Texas Instruments Incorporated. ADS825,10-Bit, 40MHz Sampling ANALOG-TO-DIGITAL CONVERTERS. Datasheet, October,1999
[48]夏闻宇Verilog数字系统设计教程.北京航空航天大学出版社.2003
[49]雷海卫,刘俊FPGA中软FIFO设计与实现.微计算机信息.2008,1(24)：207-208
[50]郑超.基于FPGA和DSP的数字式超声检测系统的研究.西南交通大学硕士学位论文.2010
[51]Volnei A Pedroni. VHDL数字电路设计教程[M].乔庐峰,王志功,等译.北京：电子工业出版社,2010
[52]TomoScan_Focus_LT_ZH_201006. www.olympus-ims.com.2010
[53]红色飓风四代Altera用户手册www.fpgadev.com.2010,4
[2]白艳.基于TOFD法的钢结构焊缝超声无损检测研究.东北林业大学硕士论文.2011：1-15
[3]马崇,吴振勇,宋力宏TOFD检测技术及测管装置.2003苏州无损检测国际会议论文集,2003：29
[4]Cho K, Hiroak,i Hisash. i Development of Simplified Ultrasonic CT System for Imaging of Weld Metal and Its Comparison with TOFD Method. JSME International Journal,2002,45(2):262-267
[5]李生田,刘志远.焊接结构无损检测技术.北京：机械工业出版社,2000
[6]白艳,邢涛.焊接结构超声TOFD法的研究现状及展望.森林工程.2010,26(5)：32-35
[7]李忠,贺艺科,等.工业管道相关标准中的无损检测要求.无损检测.2003,25(11)：597-599
[8]韩相勇,姜自安,韩曙光,等.超声TOFD技术在管道环焊缝检测中的应用.无损检测.2008,30(1)：61-63.
[9]郭学,超声TOFD方法在管道弯头检测上的应用.无损探伤.2008,32(2)：35-36.
[10]T. Miliara, Y.Otsuka and H. CHo. Time of Flight Diffraction Measurement Using Laser Ultrasound. EX Penmenial Mechanics.2006, (46):561-567
[11]B. Messer, M. Yarmuch, P.Boer. High Resolution Detection for Thermoplastic Butt-Welds in Operating Pipelines by Ultrasonic TOFD. New Pipeline Technologies, Security, and Safety.2003(1):394-399.
[12]G.Baskaran, K. Balasubramaniam and C. L.Rao. Shear-wave Time of Flight Diffraction Technique. NDT and E International.2006,6(39):458-467
[13]W. Lawson, W. Lawson. Deteetion of Defeetsin Industrial Ultrasound Images Using a Neural Network. Proceedings of SPIE-The Intemational Society for Optical Engineerin.1996, (2786):37-47
[14]P. Moura, R. Silva and H. S. Siqueira. Patten Recognition of Weld Defects in Preproeessed TOFD Signals Using Linear Classifiers. Journal of Nondestructive Evaluation.2004,23(4):163-172
[15]T. Chen, P. Que and Q. Zhang. Ultrasonic Signal Identification by EmPtrieal Mode Decomposition and Hilbert Transform. American Institute of Physies. 2005,76(8):594-600
[16]G. Baskaran, K. Balasubramaniam and C. V. Krishnamurthy. UltraSOic TOFD Flaw sizing and Imaging in Thin Plates Using embedded Signal Identification Technique. Insight Non-Destructive Testing and Condition Monitoring. 2004,9(46):537-542
[17]李衍.超声TOFD法的基础试验.无损探伤.2003,27(2)：1-10
[18]迟大钊,刚铁,等.面状缺陷超声TOFD法信号和图像的特征与识别.焊接学报.2005,26(11)：1-5
[19]刚铁,迟大钊,等.基于合成孔径聚焦的超声TOFD检测技术及图像增强.焊接学报.2006,27(10)：7-10
[20]龚铭,朱杰.边缘检测在TOFD扫描图像中的应用.电子测量技术.2007,30(7)：5-10
[21]吴军芳,滕永平,等TOFD探头性能测试及其衍射特性的研究.无损检测.2006,28(2)：64-67
[22]曹明,王巍,等.反求工程在超声衍射时差法三维建模中的应用.无损检测.2006,28(2)：73-74
[23]李衍.薄板试件的超声TOFD法缺陷定量和成像.无损探伤.2005,29(5)：1-5
[24]强天鹏,肖雄,李智军等TOFD技术的检测盲区计算和分析.无损检测.2008,30(10)：738-740
[25]StratixII GX, www.altera.com
[26]Wang Xuying, Zhang Likun, Lu YingHua. Design and implementation of high-speed real-time data acquisition system based on FPGA [J]. Journal of China Universities of Posts and Telecommunications.2006, 13(4): 61-66.
[27]田书林,王志刚,王厚军.一种多通道高速数据采集精密同步设计方法.计量学报.2010,31(1)：68-70.
[28]买培培,苏涛,齐红涛.基于FPGA的多路信号处理设计.雷达科学与技术.2010,8(3)：234-238.
[29]Yang Shujie, Guo Zonglian. Development of high-speed data acquisition system based on FPGA[J]. Electric Power Automation Equipment.2008,28(6): 93-96.
[30]江明.基于FPGA的高速数据采集系统的研制.哈尔滨理工大学硕士学位论文.2011：1-4
[31]马明建.数据采集与处理技术.西安：西安交通大学出版社,2005
[32]苏涛,张海峰,张登福.基于USB总线的实时数据采集系统设计与实现.电子技术应用.2004.
[33]诸振勇,翁木云FPGA设计及应用.西安：西安电子科技大学出版社,2002：112-207.
[34]丁安扬.基于FPGA与USB的数据采集系统的研究.成都理工大学硕士学位论文.2011
[35]冯若.超声手册.南京：南京大学出版社,2001：121-127
[36]亢彦军.超声TOFD法焊缝探伤系统的研究及开发.天津大学硕士学位论文.2007
[37]陈智发TOFD超声检测系统的研制.汕头大学硕士学位论文.2011
[38]Shyamal Mondal, Dr.T. Sattar, An overview TOFD method and its Mathe-matical Model, NDT, 2000, vol.5: 83-87
[39]钱峰.EZ-USB FX2单片机原理、编程及应用.北京：北京航空航天大学出版社,2006
[40]周立功等.USB固件编程与驱动开发.北京：北京航空航天大学出版社,2005,2
[41]Cypress. CY7C68013, EZUSB FX2 USB Microcontro] ler, www.cypress.com,2006
[42]薛圆圆.USB应用开发技术大全.北京：人民邮电出版社,2005,3
[43]Altera Corporation. Cyclone III Handbook, Volume 2, 2009, 12 http://www.altera.com.cn.
[44]张永军.基于FPGA的图像处理系统设计与算法实现研究.重庆大学硕士学位论文.2006：16-18
[45]赵宇玲.基于FPGA的信号采集与处理系统设计与实现.南京理工大学硕士学位论文.2008
[46]王诚,吴继华等AlteraFPGA/CPLD设计(基础篇).北京：人民邮电出版社.2005
[47]Texas Instruments Incorporated. ADS825,10-Bit, 40MHz Sampling ANALOG-TO-DIGITAL CONVERTERS. Datasheet, October,1999
[48]夏闻宇Verilog数字系统设计教程.北京航空航天大学出版社.2003
[49]雷海卫,刘俊FPGA中软FIFO设计与实现.微计算机信息.2008,1(24)：207-208
[50]郑超.基于FPGA和DSP的数字式超声检测系统的研究.西南交通大学硕士学位论文.2010
[51]Volnei A Pedroni. VHDL数字电路设计教程[M].乔庐峰,王志功,等译.北京：电子工业出版社,2010
[52]TomoScan_Focus_LT_ZH_201006. www.olympus-ims.com.2010
[53]红色飓风四代Altera用户手册www.fpgadev.com.2010,4